Revised Spec. No.C 9202 R3

7/28/2019 Revised Spec. No.C 9202 R3

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Ref: CGW 0001(Rev. 4)

Page 1 of 28 Date of issue February,2011 Spec. No. C-9202 (Rev.3)

INDIAN RAILWAYS

Technical Specification for Supply of Fabricated Bogie Frame / Bolster to IR for BG MainlineCoaches and BG EMU/MEMU/DMU Coaches

(13t, 16.25t & 20.32t Axle Load)SNo.

Date/month ofIssue

Revision/Amendment

Pageno.

Reasons of Revision

1 November2006

Rev. 01 2

4

4.

7

10

14

28 &

29

Change in Cl.11: Number of Employees changed from 200to 50 nos

Added new Cl. 6: Infrastructure Facilities at manufacturerswork place.

Added new Cl. 7: Fabrication of bogie frame/bolstercomponents has been given.

Details of components fitted in ICF bogie has been given.

Added new Cl. 11: Details of Fixtures & Manipulators hasbeen given.

Added new Cl 16:, Details of Gauging has been given.

Added new Annexure-3 Reference drg. Nos.of all thecomponents/parts fitted in ICF bogie of various coaching/Suburban stock provided.

2 October

2008

Rev.02 -(a) Amendment 01 of Nov. 2007 has been incorporated inC-9202 (Rev 02)(b) Annexure III at page 30 has been updated byincorporating latest drawing nos. in AC EMU (ASR), DCEMU, AC/DC EMU, and MEMU & DMU stock.(c) Detailed drawing list for the main line ASR coaches of13t, 16.25t Self Generating & End On Generating mainlinecoaches, 16.25t trailer coaches required for retro fitmentfrom coiled suspension to ASR coaches, MEMU (ASR)

motor & trailer coaches furnished in Annexure IV at page 31& 32 in the specification.(d) Amendment in clause 2.1, clause 6 and 17 specifyingshot blasting in place of grit/garnet blasting.

3 February

2011

Rev.03 Specification changed from Supply of Fabricated Bogie toSupply of fabricated Bogie Frame/Bolster .


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Technical Specification for Supply of Fabricated Bogie Frame & Bolster to IR for MainlineCoaches, EMU/MEMU/DMU Coaches

(13t, 16.25t & 20.32t Axle Load)

1. Scope:

1.1 This specification covers the technical requirements to be complied by thetenderer for manufacture, testing and

supply of Fabricated Bogie Frame andBolster to IR for Mainline Coaches, EMU/MEMU/DMU Coaches and 40,000 lts.

capacity VVN type Milk Tank Van.

1.2 This specification supercedes the earlier specification No.C-9202 (Rev.2) issued inOctober 2008.

1.3 DefinitionWherever Inspecting Agency has been mentioned it shall be taken as

Authorised Inspecting Agency of Purchaser.

2. Eligibility Criteria:

The manufacturer shall have the following:-i) Adequate fabrication, heat treatment, machining and shot blasting

facilities.

ii) ISO-9001-2000 certification.iii) Experience in manufacture of fabricated bogie frame, Bolster or otherlarge fabrications subjected to dynamic loading and vibration and shallfurnish the complete details of fabrications done in the past to RDSO forappraisal.

iv) Well-equipped laboratory for various tests required.v) Adequate technically trained staff including welders and non-destructive

testing operators for radiographic, ultrasonic and magnetic particle

inspection, qualified to approve ISI/international standards.vi) Employing a minimum work force of at least 50 persons includingsupporting personnel. Since bogie frames are also required to be heattreated, the manufacturer shall have adequate capacity both in regard toheating (furnace) and cooling under controlled condition.

Th f h ll b i id i f h b i


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3. Scope of Supply:

3.1 The fabricated bogie frame/Bolster is to be supplied conforming in all respects tothe relevant drawings as indicated inAnnexure-III.

3.2 The tenderer is required to coordinate and liaise with RDSO, Lucknow and thepurchaser during manufacture of the first two-bogie frame/bolster, which shallbe the prototype ones.

3.3 This is a general specification required for manufacturing of all types of bogieframe/bolster used in mainline coaching stock, EMU/DMU/MEMU coachingstock, Self Propelled vehicles and for 40,000lts., capacity VVN type Milk tankvan.

4. Governing Specifications:

IS:2062 - Weldable Structural SteelIS:813 - Scheme of symbols for weldingIS:817 - Code of Practice training and testing of weldersIS:2102 - General locations for linear and angular dimensionsIS:2074 - Ready mixed paint, air drying, red oxide, zinc chrome

primingIS:2932 - Enamel, synthetic exterior (a) under-coating

(b) finishing

ASTM - Straight beam ultrasonic examination of steel plates A:435

IS:3658 - Code of Practice for liquid penetrant flaw detectionIS:5334 - Code of Practice for magnetic particle flaw detection

of welds

AWS D1.1 - Structural Welding Code(1983)Blue Std. International Institute of Welding

IS:9595 - Metal arc welding of carbon and manganese.

IS:7307 - Approval tests for welding procedure.


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5. Deviation:

When deviations from original design, material specifications, dimensions etc.are desired specific proposals with reason shall be submitted for prior approvalof RDSO/Lucknow before commencement of manufacture.

6. Infrastructure facilities:The manufacturer shall have following infrastructure facility at their works formanufacturing of bogies.(i) Degreasing/Derusting plant(ii) Profile cutting machine (oxy-acetylene/plasma) for cutting plates upto

thickness 25mm)(iii) Submerged arc welding plants(iv) Edge preparation facility (planer/shapers)(v) Shot blasting plant

(vi) Load testing machine for load testing of bogies(vii) Radiographic testing facility /Ultrasonic testing machine.(viii) Furnace for stress reliving of bogie components(ix) Hydraulic press for straightening of components(x) Fixtures for fabrication and assembly of bogie components(xi) Manipulator for down hand welding of bogie components(xii) Plate bending machine

(xiii) MIG welding set with CO2/Argon as shielding media.(xiv) Apparatus to check chemical composition of steel.(xv) Hardness testing machine.(xvi) Lab for chemical & mechanical testing having

a) Universal testing machine of 400 KN or have tie up with reputedlab/agency for carrying out testing which should be ISO 9001:2000certified.

b) Impact testing machine or have tie up with reputed lab/agency forcarrying out testing, which should be ISO 9001:2000 certified.(xvii) Oven for drying electrodes (0-500 degree C)(xviii)MPI & DP testing facility.(xix) 1t/2t/5t EOT Cranes.(xx) Level surface table of size 4000 mm X 2600 mm.


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7. Bogie Frame /Bolster

7.1 Bogie frame assembly:Bogie frame assembly consists of following sub-assemblies,(i) Headstock assembly(ii) Side frame assembly(iii) Transoms assembly(iv) Longitudinal members(v) Air suspension cradle

7.1.1 Sub- Assemblies:-a) All parts/members shall be first degreased and derusted in a

degreasing/derusting plantb) All the parts/members shall be placed into the fixtures and tack welded.c) Weld the straight portion of the parts/members by submerged arc

welding and weld the curved contour by down hand MIG welding in the

manipulator.d) Stress relieving shall be done by putting the component along with fixture

into oil fired furnace equipped with thermocouples and recorders andallow to be heated between the temperature of 380 to 420C and laterallowed to cool down in furnace.

e) The assemblies shall be checked for its dimensions and inspected for itsstraightness.

f) In case the component is not straight, straightening of component shall becarried out followed by stress relieving process.

g) The above process of straightening followed with the stress relievingprocess shall be repeated till complete straightness is achieved.

h) Nose suspension bracket, shall be welded in the transom for Motor bogiesusing necessary fixture (For powered bogies only).

The sub assemblies of the bogie frame shall be placed in a fixure forfinal assembly of the bogie frame.

a) The joints between side frames with Transom, Headstock andLongitudinals shall be welded properly for non-powered bogies.

b) The joints between side frames with Transom, Head stock shall be welded


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d) Axle guides shall be welded in the bogie side frame with the help of axle

guide welding fixture.e) Alignment of the axle guide shall be checked by using master gauges andstraight edge.

f) Any slight discrepancy in location can be rectified by suitable local heatingof the frame.

g) After proper fixing of guide, the dimensions shall be recorded.

7.2 Bolster Assembly:a) All parts/members shall be first degreased and derusted in a

degreasing/derusting plantb) All the parts/members shall be placed into the fixtures and tack welded.c) Weld the straight portion of the parts/members by submerged arc

welding and weld the curved contour by down hand MIG welding in themanipulator.

d) Stress relieving shall be done by putting the component along with fixture

into oil fired furnace equipped with thermocouples and recorders andallow to be heated between the temperature of 380 to 420C and laterallowed to cool down in furnace.

e) The assemblies shall be checked for its dimensions and inspected for itsstraightness.

f) In case the component is not straight, straightening of component shall becarried out followed by stress relieving process.

g) The above process of straightening followed with the stressrelieving process shall be repeated till complete straightness isachieved.

8. Raw Material:

8.1 The chemical composition and mechanical properties of steel shall conform to IS:

2062 Fe 410 WC with Cu.

8.2 The standard steel plates conforming to IS: 2062 Gr.C Fe 410 WC with Cu shall beprocured from SAIL/TISCO or other reputed manufacturers, having theessential facilities, along with their test certificates. These test certificates shall beco-related with the stamping on the plates to be taken up for manufacture prior


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8.3 Wherever test certificates are not available, sample from each shall be drawn and

tested both for chemical composition and physical properties in the presence ofInspecting Agency.

8.4 All records of physical, chemical including impact tests shall be made availableto Inspecting Agency. All plates to be taken up for manufacture shall be visuallychecked for surface defects such as cracks, dents, pittings, bend, rust, scales etc.and they shall be free from all these defects. Straightening of the plates can bedone with the help of either straightening machine or Hydraulic press.Hammering shall not be resorted to straighten the plates.

8.5 Ultrasonic Test:All the plates shall be subjected to ultrasonic test on the entire surface fordetection of sub-surface defects or internal flaws, such as cracks, internallamination etc., in accordance with ASTM-A 435

8.6 The tested and accepted plates shall be painting suitably at several places foreasy verification at the time of tack welding.

8.7 Unaccepted plates shall be suitably stamped/painted and segregated andrecords shall be kept in proper way.

9. Cleaning, Marking and Cutting

9.1 All the plates shall be degreased and derusted before commencingmanufacturing operations.

9.2 All the plates shall be marked properly to achieve the specified dimensions givenin the drawing keeping the required allowances for proper welding and marginfor machining.

9.3 Plates shall be cut either by oxy-acetylene plasma or by machine. All nicks/cutson the plates during cutting shell be welded and finish ground before using themfor sub-assembly/assembly.

10. Edge preparation


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10.2 The weld joint dimensions/edge preparation shall be as per the relevantdrawing/IS specification.

10.3 The surfaces and edges to be welded shall be ground smooth and uniform andshall be free from cracks, undercuts, slags, gauges etc. that would adverselyaffect the quality and the strength of the weld.

10.4 The roughness of oxygen cut surfaces shall be no greater than 25 microns.

10.5 Plates shall be inspected for dimensional accuracy. Any distortion that occursduring cutting shall be straightened before tack welding.

11. Fixtures and ManipulatorsThe manufacturer should have the fixtures and manipulators for the following:i) Transomii) Side frame

iii) Air suspension cradleiv) Bogie frame assemblyv) Bolstervi) Headstock(vii) Fixture for guide fitment(viii) Lower spring seat

12. Tack welding of Assemblies

12.1 The welding surfaces and the surrounding area shall be free from loose or thickscale, slag, mill scale, moisture, grease, oil, rust etc. that would prevent properwelding.

12.2 All members to be welded shall be brought into correct alignment and held in

position by clamps, wedges, strong backs, fixtures etc. until welding iscompleted. Tack welds shall be made with the same electrodes that meet therequirements of the final welds and shall be cleaned thoroughly.

12.3 The length of tack weld and the distance between two consecutive tacks shall besuitably selected by the manufacturer to avoid defects like distortions, warpage


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13. Welding Procedure:

13.1 Filler metalMIG welding process using CO2 gas as shielding media shall be used for curvedareas where as submerged arc welding shall be used for straight areas. RDSOapproved brand of filler wire shall be adopted.

13.2 Welders qualificationQualified welder as per IS: 817 shall be employed for fabrication work and

Radiographic test shall be carried out. The edge preparation shall be inaccordance with the thickness of the plates. The welding shall reveal highstandard of workmanship. However, if welders employed are qualified to anyother international approved standards, prior approval of Inspecting Agency isnecessary.

13.3 Joints

.1 Gaps and fit-ups shall be checked before starting the welding.

.2 Use of Backing plates below the gaps of the joints is not permitted.

13.4 PositionAs far as possible, all the weld joints shall be welded in down hand position, ifnecessary by using manipulators.

13.5 Weaving bead Technique and Interpass cleaning technique shall be adopted bygrinding and using wire brushes.

13.6 Welding parameters as recommended by the electrode manufactures may befollowed.

13.7 Pre-Heat.1 Interpass temperature of 150 degree C to 200 degree C shall be maintained

throughout the welding..2 Electrodes shall be pre-heated, in the electric ovens, to a temperature of

150 degree C to 250 degree C for 2 hours before they are used.

14. Quality of Weld joints


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Date of issue February,2011 Spec. No. C-9202 (Rev.3)

.1) Weld joints shall have uniform beading and smooth change over fromweld deposit to the parent metal and thorough fusion between adjacentlayers of weld metal and between weld metal and parent metal.

.2) They shall be free from cracks, craters, undercuts, overlaps, porosities,inclusions, blow-holes etc.

.3) The fillet weld profile shall be made concave by grinding so that smoothtransition occurs at the toe of weld maintaining correct size of the welds.

.4) The slags shall be thoroughly removed and cleaned after each interpass.

.5) The welds shall be ground to eliminate stress raisers and to improvefatigue life.

.6) Members distorted by welding shall be straightened by carefully

supervised application of heat. The temperature of heating areas shall notexceed 650 degree centigrade. Mechanical method may also be used withapplication of heat. All the rework and straightening operations shall becompleted before stress relieving.

14.2 Magnetic Particle Test/Dye Penetrant Test.1) All the fillet weld joints shall be subjected to Dye Penetrant Test on all

critical areas, as indicated in relevant Drawings listed in Annexure-I andall the butt weld joints (100%) shall be subjected to Magnetic ParticleTest/Dye Penetrant Test for detection of weld flaws. The procedure andacceptance standard shall be as per IS specification no.5334/3658respectively.

.2) Evaluations

Discontinuities and defects shall be indicated by retention of the magneticparticles and rise of Dye Penetrating after applying developer on thesurface of welds shall indicate discontinuities and defects. All suchindications are not necessarily the defects, since excessive surfaceroughness, and the heat-affected zones etc. may produce similarindications. Even if indications are believed to be non-relevant, each type


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.1) All linear discontinuities are un-acceptable and shall be removed andrepaired by chipping or grinding and subsequent welding.

.2) When defects appear, they shall be rectified and the area shall be re-examined by the same method to verify that they have been rectifiedcompletely.

.3) All test reports of Magnetic particle inspection/Dye Penetrant Test will besubmitted for review to the Inspecting Agency.

14.4 Radiographic/Ultrasonic Examination

.1) All the Butt weld Bevel joints shall be subjected to 100% RadiographicTests at 2% sensitivity and 2.0-2.2 film density conforming to BlueStandard of International Institute of Welding (IIW).

.2) As per the specified standards IIW Weld joints having cavities, undercutsand porosities shall be within the acceptable limits as per the specified

standards.

.3) The Radiographic examination shall be carried out by qualified personneland radiographs shall be submitted to the inspecting agency forinterpretation. In case of difference of opinion, the interpretation ofInspecting Agency will be final.

.4) Alternatively Ultrasonic testing of welded joints shall be carried out as perM&C dtes Code of Practice No. MC-4 of November 1994 (Reaffirmed inMarch 2005).

15. Stress Relieving:

The stress relieving of the bogie frame/bolster shall be carried out in an oil-fired

furnace equipped with thermocouples and recorders. Adequate measures shallbe taken to avoid any appreciable distortion of the bogie/bolster during heattreatment. If any resetting is required to be done after heat treatment in order toachieve required dimensions, the bogie frame/bolster shall be again suitablyheat treated after such re-setting.


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i) Longitudinal gauge for axle guide. (As perICF Drawing No J&T/G0296/01)

ii) Transverse gauge for axle(As per ICF Drawing No J&T/G0384/01)

iii) Diagonal gauge for axle guide.(As per ICF Drawing No J&T/G0300/01)

16.1 Square ness of the bogie frame, axle guides and BSS brackets shall be checkedwith the help of transverse, longitudinal and diagonal gauges and straight edge.Axle box alignment shall be checked with reference to the BSS brackets with thefollowing gauges.

S.No. Gauges 13 t bogies 16 t bogies 20.32 t

bogiesMain Line &DMU Stock

EMU/MEMU Stock

1 Longitudinal gaugefor axleguide

5701.0mmequidistant fromcentre line of axle

5701.0mmequidistantfrom centreline of axle


630 mm

2 Transverse

gauge foraxle guide

21591.0mm 21591.0mm 21591.0m

m

2210 mm

3 Diagonalgauge foraxle guide

36121.0mm 36121.0mm 36121.0mm 36431

mm

4 Longitudinal gaugefor BSSbrackets

14001.0mm(7000.5mm fromlongitudinal centreline)

15001.0mm(7500.5mmfromlongitudinalcentre line)

13401.0mm(6700.5mm fromlongitudinal centreline)

8001mm

5 Transversegauge for

21591.0 mm 21591.0 mm 21591.0mm

21401mm


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BSSbrackets

7 DistancebetweenBSS bracketandadjacentaxle guide

4631.0mm 4131.0mm 4931.0mm 7331.0mm

8 TransverseGauge forBrake beamhangerbracket.

8761.0mmequidistant fromcentre line of axle



8751.0mmequidistant fromcentreline ofaxle

16.2 If the BSS brackets do not lie within the tolerances relocate one or more BSSbrackets with correct alignment after ensuring correct alignment of the BSSbrackets. Measure the location of axle guide from BSS bracket. If thesemeasurements deviate from the standard measurements, relocate this alignedplane of axle guides.

17. ShotBlasting:

17.1 The entire bogie frame/bolster shall be subjected to shot blasting after heat-treatment for cleaning of rust, scales, spatters etc. Special care shall be taken toprotect the threads of Axle box guide during shot blasting.

17.2 Immediately after shot blasting and inspection the bogie frame/bolster shall becoated with one coat of anti-corrosive paint to spec. no. IS: 2074 in order to arrest

rusting and corrosion.

18. Marking of Bogie Frame/Bolster

The bogie frame/bolster shall be placed on the marking table in order to ensurethe following:


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Record of above checks and Dimension Control Chart shall be submitted to theinspecting agency on demand.

19. Painting

The bogie frame/bolster shall be given one coat of Red Oxide Zinc Chromate toIS: 2074 followed by two coats of black synthetic enamel paint to IS: 2932.

20. Stages of Inspection:

20.1 The inspection shall be carried out by inspecting agency as indicated below:.1) Stage inspection of major sub-assemblies consisting of:

a) Side framesb) Bolstersc) Axle box guidesd) Air suspension cradle

e) Headstockf) Transomsg) Longitudinal Members

.2) Inspection after the above parts are assembled and tack welded.Special care shall be taken to maintain the centers of Axle boxguides and bolster spring suspension brackets.

.3) Inspection of complete bogie frame/bolster after complete welding.

20.2 After completion of the First Two Bogie Frames/Bolster, waiving of any or allitems of the stage inspection may be considered by RDSO/Purchaser on requestby the manufacturer. This will depend upon the experiences gained at the timeof inspection of first two bogies/bolsters and the level of confidence built-up.The manufacturer will proceed further in fabricating bogie frames/bolsters onlyafter taking clearance at each stage as specified above.

20.3 The Purchaser/Inspecting Agency shall have access at all reasonable times to theworks where bogie frame/bolster is manufactured and material is stored and theright to inspect die, jig and fixtures and measuring instruments being used by the


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20.4 Dimension Control Charts, Chemical and Mechanical properties test certificates,Magnetic Particle Test Certificates, Radiography Test Reports, Heat Treatmentrecords etc. shall be supplied along with the Bogie Frames/Bolster to thepurchaser.

21. Dimensions and Tolerances

21.1 All dimension/tolerances shall be as per details given in the drawings.However, special attention shall be given to check the centers of axle box guides

and bolster spring suspension brackets in longitudinal, lateral and diagonaldirections.

21.2 Detailed dimension control charts/ sheets shall be prepared for each bogie framein which measurements of critical dimensions shall be recorded and kept forevaluation and verification by the inspecting agency.

21.3 All the un-toleranced dimensions shall be in accordance with IS: 2102-1980(Medium) as indicated in the drawing.

21.4 Gauges, fixtures and templates and accurate measuring instruments shall beused to ensure the correctness of the dimensions.

22. Periodic Calibration of Gauges and Fixtures

The gauges, fixtures and templates shall be calibrated/checked for its correctnessand accuracy after every six months and records shall be kept in proper way asper ISO: 9001 requirements.

23. Q.A.P

A Quality Assurance Plan which outlines the various processes includinginspection in order to obtain a Quality product shall be submitted to RDSO forapproval and QAP shall be prepared on the lines as indicated in ISO: 9001document, CGG 0001(Rev 01) Vendor approval guidelines.


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24. Code of Practice for Quality Control and Inspection

24.1 The system

The manufacturers shall furnish to the purchasing/inspecting authoritiesinformation in respect of quality control systems in force at their works onvarious materials used in the manufacture of components.

24.2 Records, Tests & Sampling

The manufacturers shall furnish the Purchasing/Inspecting authorities thedetails of tests and inspection records and other relevant records as requiredunder the quality control systems in force.

These records and reports shall be maintained by the Competent TechnicalAuthority of the manufacturer and shall be open to examination by the

Purchasing/Inspecting Authorities at all reasonable time. ThePurchasing/Inspecting Authorities at their discretion may draw samples ofmaterials referred to in para 8 and products at any stage of production forconformity tests either at the works of the manufacturer or in an approvedlaboratory. In case the samples do not conform to the requirements of thespecification, double the number of samples from the same lot/batch shall bedrawn for re-tests. Should any of the re-test samples do not conform to the

requirements, the entire lot/batch shall be rejected.

24.3 Approved Manufacturers

24.3.1 For reasonable quality assurance, it is desirable that the components areprocured from manufacturers approved by Research Designs & StandardsOrganisation (RDSO), Lucknow or by any other agency as assigned by thePurchasing Authority, based on evaluation of the components as per thespecification, manufacturing and quality control facilities and quality/assuranceprogramme. However, such approval does not guarantee the supply ofconsistent quality of material/components and therefore every lot/batch offeredshall be subjected to inspection and testing as per the specification.


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laboratory for conformatory tests within six months from the date of receipt ofthe supplies.

25. Identification Marking:

Each bogie frame/bolster shall be provided with an easily visible identificationplate indicating the bogie frame/bolster serial number year of manufacture andmanufacturers name to facilitate identification/correlation with theinspection/test results.

26. Packing:

26.1 All machined surfaces shall be protected from oxidation and corrosion byapplying two coats of rust preventive oil to IS spec. No.493 Pt.I viscosity grade46.

26.2 The packing shall be such that all the machined surfaces shall be properlyprotected against rubbing/impact/scratches with each other or with mode oftransportation i.e. wagon/truck/trailers etc.

27. Warranty:

The manufacturer shall warrant the bogie frame for a period of 5 years from the

date of commissioning into service for material, manufacture and workmanshipas regards trouble-free and satisfactory service performance. If any defects arenoticed during service with regards to manufacture/welding quality of the bogiefame, action shall be taken by the supplier to carry out any repairs/rectificationor replacement, as may be considered appropriate, which shall be done at hisown cost. The decision of the purchaser in this regard shall be final.

28. Submission of Tender Offer:

The tenderer shall submit parawise comments on this specification in his offer.In the absence of parawise comments, his offer will stand rejected. He shall bringout the deviations, if any from the specification with adequate justification forsuch deviations. Unless otherwise stated in his offer, it will be presumed that


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29. Purchase of Drawings:All ICF drawings mentioned in the specification shall be obtained from ICF

Chennai. The drawings and technical details would be provided by ICF freeof cost, but incidental charges connecting with preparation and printing ofdrawings and cost of booking of staff would be paid to ICF at actuals.

30. Static Load Test :1. The static load test on bogies shall be conducted on level plane for first two

prototype bogies of every order.

2. Bogie frame along with bolster assembly shall be placed on test rig. Axle boxsprings and bolster springs of the bogie shall be replaced by providing solidcylindrical spacers of 300mm height at axle guide (Location at a b c & d) andalso at secondary suspension (Location at P & Q).

3. Arrangement shall be made for measuring load deflection at the center of theside frame (Location at A&B) by providing dial indicator gauges with suitablefixing arrangement, initial setup at 00.

4. The predetermined load, required for this test, which is given in the tablebelow according to the type of bogie, shall be applied simultaneously at theside bearer on the bogie bolster (location at X & Y).

5. The deflection of the side frame at location A & B shall be observed andrecorded as per the proforma below. This should not be more than 1mm.

6. The applied load shall than be removed from the side bearer and the residualdeflection (if any) is observed and recorded. This residual deflection should

be nil.7. The sketch of the load testing equipment is given on page 27 on thisspecification

S.No.

Axle load

(t)

Max. loadapplied onside bearer

(t)

Deflection under Max.load at the center of

side frame location at

Residual deflection (ifany) after removal of

load at location

Remarks

A

(mm)

B

(mm)

A

(mm)

B

(mm)1 13 6.530

2 16.25 8.547


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Annexure-I

Location of Radiographic and Dye Penetrating Test on Bogie frame and bolster

Type of Bogie Drawing References

Radiographic Examination Dye penetrant test

Bogie frame Bolster Bogie frame Bolster

Trailer bogies of

MEMU/DMU andMainline bogies (all coiledtype)

SK-92064

(At page no.-22)

SK-92063

(At page no.-21)

SK-92077

(At page no.-24)

---

Motor bogie & HCC bogieof EMU (all coiled type)

SK-92078(At page no.-25)

--- SK-92076(At page no.-23)

---


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Annexure-II

RECOMMENDED STRESS RELIEVING PROCEDURE

1) The temperature of the furnace shall not exceed 315 degree centigrade at the timethe welded assembly is placed in it.

2) Above 315 degree centigrade, the rate of heating shall not exceed 160 degreecentigrade per hour. During the heating period, variation in temperature

through the portion of the part being heated shall not be greater than 50 degreecentigrade. The same shall be monitored by measurement of temperature usingsuitable thermocouples. For bogie frame, 4 thermocouples shall be fixed at thefour corners and two at the centre of the side beams.

3) Soaking temperature shall be between 600 degree centigrade and 650 degreecentigrade. On reaching the temperature, the assembly shall be held within

specified limits for a time not less than 1 hour per 25mm thickness of the plates.

In addition, for determining the soaking time, the thickness of the thickest part ofthe assembly shall be considered. During the soaking period, the differencebetween the highest and lowest temperature of the assembly shall not be greaterthan 50 degree centigrade.

4) During cooling cycle upto 315 degree centigrade cooling of the job shall be donein a closed furnace at a rate not greater than 100 degree centigrade per hour.From 315 degree centigrade, the assembly may be cooled in still air.

5) Suitable tie-bars shall be provided during stress relief operation for maintainingthe critical dimensions. The assembly shall be kept in the furnace, bottom sideup (inverted position) during the heat treatment.

6) The assembly shall be suitably supported while loading in the furnace to avoidany permanent deformation during stress relieving operation.

7) The heat-treating furnace temperature shall be effectively controlled by usingthermocouples having associated recording equipment.


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R f CGW 0001 P 27 f D f i F b 2011 S N C ( )


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Signature

Name &Designation

Prepared By-P.K.Sachan /SSRE

Checked By-P.K.Srivastava /ADE/VDG

Approved By-Shivendra Singh /J t. Director/VDG

Annexure-IIIS.

No.

Description

Mainline Bogies (ASR) * MEMU (ASR)16.25t(ASR)

Trailer (Forretrofitment

of existing coaches)SG

(13t)SG

(16.25tEOG

(16.25t) Motor Trailer

1 Axle load 13t 16.25t 16.25t 20.32t 16.25t 16.25t2 Bogie genl. arrgt. CA00002 CA00001 WTAC4-0-0-401 ACEMU/M/

ASR-0-0-001alt-h R

ET00002 AC EMU/C/ASR-0-0002

3 Axle box guide arrgt. CC01100 AW01100 WTAC3-0-1-304 EMU/M-0-1-033 col-III ET01100 EMU 0-1-018

4 Roller bearing axlebox

WTAC3-0-2-304 EMU/M-0-2-001 col-IX

CC02100 WTAC3-0-2-304

5 Bogie frame arrgt. CA03105 CA03100 WTAC3-0-1-402 EM03100 ET03150 ACEMU/C/ASR-0-3-003

6 Bogie side frame CA03104 CA03101 WTAC4-0-3-408 DMU/DPC-0-3-002

ET03181 EMU 0-3-069

7 Head stock RB03104 AW03226 WTAC3-0-3-314 EMU/M-0-3-004 ET03101 EMU 0-3-0688 Transom RB03146 AW03125 WTAC4-0-3-403 EM03117 ET03106 EMU 0-3-0679 Longitudinal members RB03106

RB03164AW03221AW03127

WTAC4-0-3-404 N.A. ET03100ET03143

EMU 0-3-070

10 Bogie bolster arrgt. CA04100 CA04100 WTAC5-0-4-501 EM04110 ET04130 ACEMU/C/ASR-0-4-004

11 Centre pivot arrgt. CC06100 CC06100 T-0-6-601 EMU/M-0-6-001col-IV

CC06100 EMU 0-6-001

12 Anchor link CC07130 CC07130 WTAC5-0-7-501 N.A. ET07104 EMU 0-7-00113 Shock absorber

Verticalcapacity

DMU/DPC5-0-5-503(600 Kg)

DMU/DPC5-0-5-503(600 Kg)

Chair car- 600kg.Power car- 900kg.

DMU/DPC5-0-5-503

(900 Kg)

DMU/DPC5-0-5-503(600 Kg)

DMU/DPC5-0-5-503.

14 Shock absorberLateralcapacity

DC/EMU/M/ASR-0-5-005

(100Kg)


(100Kg)

Chair car- 100kg.Power car- 400kg.

DC/EMU/M/ASR-0-5-005(100Kg)


(100Kg)


.15 BSS hangers N.A. N.A. NA N.A. N.A. NA16 Axle box coil spring CC01129 AW01101 WTAC3-0-1-202 DMU/DPC-0-1- ET01001 DC/EMU2-0-1-203

R f CGW 0001 P 28 f D t f i F b 2011 S N C 9202 (R 3)


28/28


Page 28 of28


Signature

Name &Designation

Prepared By-P.K.Sachan /SSRE

Checked By-P.K.Srivastava /ADE/VDG

Approved By-Shivendra Singh /J t. Director/VDG

00117 Bolster suspension

arrgt.CA05100 CA05100 WTAC3-0-5-305 EM05102 ET05120 ACEMU/C/

ASR-0-5-00418 Bogie brake arrgt. CC32272 AW32122 WTAC4-3-2-401 EMU/M-3-2-064

Col- IET32111 DC/EMU 3-2-006

19 Suspensiondiagrammatic arrgt.

CA90001 CA90001 DMU/TC29-0-204

EM90003 ET90003 ACEMU/C/ASR-9-0-003

20 Wheel & axle arrgt. CG-K6016 CG-K6016 CG-K6016 EMU/M-0-1-027 ET02102 EMU-0-2-00721. Remarks * To be applicable only after issue of speed certificate.

Documents

Revised Spec. No.C 9202 R3